Construction for furnaces



July 26, 1938. H. A. MORLOCK CONSTRUCTION FOR FURNACES Filed Dec. 24, 1937 HurggyAMoflock,

ATTORNEYS Patented July 26, 1938 UNITED STATES PATENT OFFICE 14 Claims.

This invention relates to furnace construction and it has particular relation to structure and arrangement of refractory elements or building blocks employed in building furnaces.

One object of the invention is to provide an improved furnace wall construction.

Another-object of the invention is to provide an improved arrangement of compound building blocks in furnace construction.

Another object of the invention is to provide an improved combination of refractory element and metal covering for use in building either furnace walls or roofs.

Another object of the invention is to provide an improved combination of building blocks, metal. joints and cementing or fluxing material in a furnace construction.

Another object of the invention is to provide a furnace construction which is provided with oxidized metallic joints between refractory blocks and in which a fiuxing agent has been included to enhance the bonding of the elements of the furnace construction.

The invention is related to and constitutes improvements over the disclosures in my co-pending application Serial No. 164,898, filed September 21, 1937.

One feature of the invention involves thedevelopment of an improved arrangement for utilizing the advantages of the iron oxide joint while at the same time minimizing the deleterious features of crystalline growth and promoting economy in the manufacture of the components for so doing by providing for only. a single thickness in all joints between adjacent and contacting tiles or masses in the furnace construction.

I have devised a method whereby the valuable efliciency of the metal-plate joint can be increased and also projected for use in lower temperature ranges than heretofore possible. To this end, a fluxing medium is applied to the surfaces of the metal covering which are in contact-with the refractory tile. By the introduction of such flux, or third factor, the metal-plate refractory joint is made to follow the law of ternary compounds in respect to their temperature concentration equilibrium phenomena. In such combination, the oxidized metal plate, plus the added flux, combine with the refractory to form a ternary, reaction or fusion compound. The flux being of a relatively low fusion point tends to lower the fusion point of the ternary compound and, in any temperature range above the fusion point of the added flux. a liquid constituent of relatively low fusion point is formed. Such liquid constituent is in part dependent in amount on the amount of oxidized metal plate in the joint and upon the amount of the added flux. Such liquid constituent in penetrating the inter-crystalline interstices of the oxidized metal plate tends to become richer in iron-oxide and poorer in flux,

and thus, its fusion point is raised to a point where freezing occurs. Such liquid as penetrates into the pore spaces of the refractory tile tends to dissolve and combine with the preponderating refractory at the same time its own concentration is diminished, and thus, there is an increase in fusion point with freezing resulting.

The physical result of these processes is a greater penetration of the fusion products into the refractory and ultimate solidification in the penetrated zone with greater strength of joint resulting therefrom.

,A practical flux for this purpose is borax, although other substances such as silicate of so'- dium, sodium fluoride, etc., which will act as suitable fiuxes, can be used. To expedite easy application of the fiuxing medium and retention in proper placement during shipment or handling,

the fiuxing medium should be applied to the inner and outer surfaces-of the metallic covering before such covering is applied to the tile. Such fluxes can be readily applied while dissolved or suspended in a suitable liquid vehicle. Linseed oil can be used as a suitable vehicle to place the flux, as an adhering film on the metallic plate surfaces. This invention, however, is not limited to the use of linseed oil as a vehicle for the added flux as any other suitable liquid orany other drying oil which will distribute and hold the flux 3 as a film on the metallic surface can be used. It is not imperative that the flux-film application be made to the metallic covering, but it is less economical to apply such film to the tile surfaces. In application to the tile the high absorption into the pore spaces of the tile would require the consumption of a greater amount of the fluxing vehicle to produce the necessary flux film than is true when making the application to the non-porous metallic covering.

In the drawing:

Fig. 1 is a perspective of a section of furnace construction in which the invention has been incorporated;

Fig. 2 is a perspective of a compound refractory and metal block for building furnaces;

Fig. 3 is an elevation of a section of furnace construction in which alternate forms of encased and unencased refractory blocks are provided;

ing structure (not shown) shaped plate I6 is cut away; as indicated at 26,

Fig. i is an elevation ofa section of furnace construction in which substantially one-half of each refractory block is encased in metal;

Fig. 5 is a perspective of a form of metal casing or covering employed in the construction shown in Fig. 4; I

Fig. 6 is a perspective of another form of metal plating or covering for refractories; and

Fig. 7 is a perspective of an arrangement of a compound refractory and metal block construction for accommodation of tuyres.

In one form of the invention shown in Fig. l, a section of furnace construction I0, is composed of refractory blocks H of tile or brick, each of which receives a web of an angular plate 16 of oxidizable metal arranged to lie .against and cover one side I! thereof. Opposite I legs 20 of the plate extend approximatelyonehalf the distance along opposite sides 22 of each refractory block. Hence, one-half of the contacting side surfaces of each block is plated, leaving proportionate side surface portions of the block unplated. These blocks of refractory material are oblong in form and their end surfaces are not necessarily plated.

The several blocks are laid in such manner in the furnace construction that the legs 20 of the U-shaped plates I6 extend alternately in opposite directions, and hence, the web l5 of one plate contacts directly along the bare or unpiated surface of an adjacent block, while the legs 20 of adjacent plates serve to cover or plate substantially the entire side surfaces adjacent those covered by the webs 55. Accordingly in all of the joints among the several compound refrac-' In the form shown in Fig. '2, the refractory" block I2 is of such character as to be suitable for certain types of furnace roof construction vin'which the blocks are recessed, as indicated at 25, to facilitate its suspension in roof support- A part -of the U- to provide proper space for the recessed portion. In building a furnace incorporating this form of plated refractory, the structure is assembled in substantially the same manner as that shown in 1, although it may be of different contour.

Referring to the arrangement shown in Fig. 3,

a four sided plate casing is applied to one refractory block l2 while an adjacent refractory block remains unplated. By alternately laying encased or plated blocks and unplated blocks, a single thickness of metal is insured among the joints of the masonry structure. Intermediate side portions of the casing 30' are sprung inwardly and the refractory blocks I2 are forced therein, whereby the resiliency of the sides provides for the latter securely gripping the blocks.

In Figs. 4 and 5, there is shown a section of furnace construction 33 in which each of the refractory blocks I? is provided with an angular metal plate 35 having its sides 35 covering adjacent sides of the block from end to end of the latter. Both of the plate sides 36 along their outer marginal portions are provided with tongues 31 which can be bent into engagement with recesses 39 formed in the refractory blocks i2. In an arrangement of this kind, the plates '35 are secureiy fixed upon and cover two adjablock i2 is covered with a plate side 40 of similar extent, and flanges 42 extend from opposite edge portions of this side 40. These flanges 52 are disposed at opposite end portions of the plate side 40 and are arranged in alternate relation in the furnace construction. Therefore. a flange 42 partially plating one side of a biock constitutes substantially a continuation a similar flange on an adjacent block, and asingle uniform thickness of metalis thus provided in the joints of the masonry.

In Fig. 7 the arrangement of the refractory blocks l2 and metal plating I6 is similar to that shown in Figs. 1 and 2, with the exception that recessed portions extending from end to end of the blocks providesuitable tuyere openings;

for example, the type conventionaiiy employed in copper bessemerizing converters. The legs 20 on the sides of the blocks in which the recesses are formed are terminated at the opening.

In the forms of structure shown in Figs. 1 to 3, 6 and '7, the metal plate coverings I5, 30 and 40 are resilient and are sprung upon the blocks l2. In construction shown in Figs. 1, 2 and "i the tightly grip the blocks, and in the construction shown in Fig. 6, a similar action is insured by springing the legs or sides e2 upon the blocks I2. In the arrangement shown in Fig. 3 the sides of the metal containers 30 are first sprung inwardly and then are forced outwardly and remain under tension in their normal block engaging shape, as shown.

in all of the forms of the structure shown and described, it should be understood that suitable fiuxing agent is applicable in the joints and in the manner above described, either by applying such agent directly to the inner and outer sides of the plating, or, if found practicable,'to the surfaces of the refractory blocks. Then upon application of heat incidental to the use of the furnace, the oxidation of the metallic plates and bonding of the refractory surfaces is effected to legs or flange sides or legs 20 are sprung and to a minimum in the single uniform thickness 7 of metal provided therein. Hence, undesirable grain growth or crystalline growth-is minimized,

and because of the uniformity of distribution of the metal or iron oxide in all joints, unavoidable stresses in the furnace construction are likewise uniformly distributed. These advantages enhance the durability of the furnace construction and provide for improvement in the operation thereof.

Although several forms of the invention are shown and described in detail, it will be apparent to those skilled in the art that the invention is not so limited, but that various changes can be made therein without departing from the spirit of the invention or from the scope of the appended claims.

I claim:

1. In a furnace construction, a section of ma-' sonry including a plurality of refractory blocks, each blockh'aving a corner portion extending from end to end thereof and having plated portions on the block sides adjoining said corner portion, said plated portions including oxidizable metal, and companion refractory blocks having corner portions running from end to end thereof and having unplated side portions adjoining said corner portions, plated portionsof the first plurality of blocks being abutted against unplated portions of said companion blocks whereby a single thickness of metal plating is provided in the joints of the masonry.

2. In a furnace construction, a section of masonry including a plurality of refractory blocks, each block having a corner portion extending from end to end thereof and having plated portions on the block sides adjoining said corner portion, said plated portions including oxidizable metal, and companion refractory blocks having corner portions running from endto end thereof and having unplated side portions adjoining said oxidizable metal, companion refractory blocks having unplated side portions running from end to end thereof, plated portions of the first plurality of blocks being abutted against unplated portions of said companion blocks whereby a single thickness of metal plating is provided in the joints of the masonry.

4. In a furnace construction, a section of masonry including a plurality of refractory blocks, metal plating covering one side of each block,

said metal plating having flanges formed along,

opposite marginal portions thereof and extending along portions of the sides of the block adjoining opposite edges of said one side of the block, portions of each block remaining unplated, plated portions of the blocks being abutted against unplated portionsof adjacent blocks whereby a single thickness of metal plating is provided in the joints of the masonry.

5. In a furnace construction, a section of masonry including a plurality of refractory blocks, U-shaped metal plating extending approximately from end to end of each block and covering approximately one-half the side surfaces thereof with unplated side surfaces of the block projecting from the plating, plated and unplated sides of the several blocks fitting in alternate relation and providing substantially. continuous and uniform single thickness of metal plating in the joints of masonry.

6. In a furnace construction, a section of masonry including a plurality of refractory blocks laid in courses, the refractory blocks in one course 'being alternately metal plated and unplated, the

metal plating entirely surrounding the blocks upon which it is applied from end to end thereof, the refractory blocks in a course adjacent said one course also being alternately metal plated and unplated, the metal plated blocks of one course being abutted against the unplated blocks of the other course whereby a substantially continuous and uniform single thickness of metal plating is provided in the joints of the masonry section.

'7. In a furnace construction, a section of masonry including a plurality of refractory blocks, an angular metal plate disposed along two adjacent Sides of'each block from end to end of the latter, two other similar sides of the block remaining unplated, said refractory blocks being laid in courses, unplated sides of the blocks of one course abutting plated sides of the blocks of an adjacent course, unplated sides of blocks in each course being abutted against plated sides of other blocks.

8. In a furnace construction, a section of ma-' sonry including a plurality of refractory blocks, an angular metal plate disposed along two adjacent sides of each block from end to end of the latter, two other similar sides of the block remaining unplated, said refractory blocks being laid in courses, unplated sides of the blocks in one course abutting plated sides of the blocks of an adjacent course, and unplated sides of blocks in each course being abutted against plated sides of other blocks, portions of each block having recesses therein, and angular projections on each metal plate engaging in the recesses to secure the plate upon each refractory block.

9. In a furnace construction, a section of masonry including a plurality of refractory blocks having plated side portions extending from end to end thereof, said plated portions including oxidizable metal, companion refractory blocks having unplated side portions running from end to end thereof, plated portions of the-first plurality of blocks being abutted against unplated portions of said companion blocks and providing a single thickness of metal plating throughout the joints of the masonry, said oxidizable metal being resilient and sprung upon the blocks in gripping relation.

10. In a furnace construction, a section of masonry including a plurality of refractory blocks, U-shaped metal plating extending approximately from end to end of each block and covering approximately one-half of the area of the side surfaces. thereof with unplated side surfaces of the block projecting from the plating, each leg of the U-shaped metal plating of each block covering approximately one-half the block side it contacts, plated and unplated sides of the several blocks fitting in alternate relation and providing substantially continuous and uniform single thickness of metal plating throughout the joints of the masonry.

11. In a furnace construction, a section of masonry including a plurality of refractory blocks, U-shaped metal plating extending approximately from end to end of each block and covering approximately one-half of the area of the side surfaces thereof with unplated side surfaces of the block projecting from the plating,-each leg of the U-shaped metal plating of each block covering approximately one-half of the block side it contacts, the legs of the U-shaped metal plating of each block being resilient and sprung in gripping relation upon each block to prevent separation of plating and'block, plated and unplated sides of the several blocks fitting in alternate relation and providing substantially continuous and uniform single thickness of metal plating throughout the joints of the masonry.

12. In a furnace construction, a section ofmasonry including a-plurality of refractory blocks having plated side portions extending from end to end thereof, said plated side portions including oxidizable metal, companion refractory blocks having unplatedside portions running from end to end thereof, plated portions of the first plurality of blocks being abutted against unplated side portions of said companion block and providing a single thickness of metal plating throughout the joints of the masonry, and a fluxing agent in the joints of said masonry and responsive to heat in the furnaceto facilitate the oxidation of the metal and the resulting bonding of the surfaces in the joints.

13. In a furnace construction, a section of masonry including a plurality of refractory blocks having plated side portions extending from end to end thereof, said plated side portions including oxidizable metal, companion refractory blocks having unplated side portions running from end to end thereof, plated portions of the first plurality of blocks being abutted against unplated portions of said companion blocks and providing a single thickness of metal plating throughout the joints of the masonry, said metal including a fiuxing agent applied to all surfaces thereof and responsive to action of heat in the furnace to facilitate the oxidation of the metal and chemical reaction between the'refractory surfaces and metal.

14. In a furnace construction, a section of masonry including a plurality of refractory blocks having opposed faces defining masonry joints,

single thickness-of metal disposed in each joint between opposed faces of the blocks, and a fluxing agent in all the joints and having combining amnity with both the metal and refractory blocks and responsive to heat in the furnace to facilitate oxidation of the metal and resulting bonding of the surfaces in the several joints of the masonry.

HARRY A. MORLOCK. 

